Convertible Package Assembly

ABSTRACT

A case formed from a single piece of material can be deconstructed simply and placed on a store shelf without the need for tools. The case has asymmetric portions can hide tear lines from the end consumer. Further, the case can be filled with product containers in a first orientation and shipped or placed on a shelf in a second orientation.

CROSS-REFERENCE TO RELATED APPLICATIONS

None

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable

BACKGROUND

Shipping packages, such as corrugated, cardboard and/or paperboard boxes, trays and similar assemblies are commonly used to contain a plurality of products or product containers for transport of such products from the manufacturer, to their eventual retail environment. Upon arrival in a retail environment it is desirable to store or display these products on shelves so that the goods and products are conveniently visible and accessible by a user. Thus, some package assemblies have been designed to be convertible from a shipping configuration to a display configuration (shelf ready packaging (SRP)).

Despite the plethora of unique convertible package assembly/display systems that are available, there remains a need for improved systems that are even more dynamically useful, environmentally friendly and cost effective.

U.S. Application Nos. 61/869,117, filed Aug. 23, 2013, and Ser. No. 14/255,320, filed Apr. 17, 2014 and published as U.S. Pub. No. 2015/0053587 are incorporated herein by reference.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS(S)

A detailed description is hereafter described with specific reference being made to the drawings.

FIG. 1 shows a top view of an embodiment of a blank 30 for forming a package assembly 10.

FIGS. 2 and 3 show three-dimensional views of an embodiment of the package assembly 10 as it is being constructed from the blank 30.

FIGS. 4 and 5 show three-dimensional views of an embodiment of the package assembly 10 as it is being loaded with product containers 50.

FIGS. 6 and 7 show three-dimensional views of an embodiment of the package assembly 10 as it is being further constructed.

FIG. 8 shows a three-dimensional view of an embodiment of the package assembly 10 in a reoriented configuration.

FIGS. 9 and 10 show three-dimensional views of an embodiment of the package assembly 10 as it is being deconstructed for use.

FIG. 11 shows further detail of a hidden tear strip of the package assembly 10.

DETAILED DESCRIPTION

Embodiments having desirable characteristics of a Shelf Ready Package (SRP), as specified by the nation's leading retailers, are disclosed herein. Per retailer guidelines, secondary packaging must be able to withstand the rigors of the supply chain, preserving product integrity and aesthetics of the primary package. A Flange Seal Case, as described herein, offers equivalent strength of a Regular Slotted Case (RSC) in a similar thickness of corrugated material by providing corner supporting members in the form of overlapping sections. In the shipping orientation, these members form 90 degree column-like supports with the corrugated flutes in the direction of the palletized load.

Additionally, the case is easily convertible upon shelf placement in the retail store. In particular, embodiments of the case herein disclosed contribute to an efficient shelf replenishment process and can be opened simply without the aid of tools. Further, embodiments offer superior aesthetics while simplifying the conversion from shipping mode to shelf-ready mode.

Forming cases that satisfy the specifications of retailers presents additional challenges. For example, retailer requests with respect to aspect ratios of shelf depth, width, and height can be difficult to produce due to machine capabilities. Consequently, there remains a need to provide cases that utilize single-facing or single product width (SPW) which can be formed without significant modification to machines. SPW cases are desirable because of the immense variety of products and flavors that retailers currently offer and SPW cases permit the retailer to make efficient use of the width and depth of the shelf space.

Additionally, single product height (SPH) is commonly one unit in the vertical direction. With flexible containers or pouches, a SPH and SPW are used almost exclusively. As a result, an opening or slot (typically narrower width and comparatively taller height) in the retailer's shelf is where the product must be shelved. Typical shelf depth (SD) is approximately 20-24 inches. And, in traditional case designs, case forming machines will use the SPW×SPH as the mandrel size or opening. U.S. Publ. No. 2015/0053587 is illustrative.

In some instances, SPW×SPH creates aspect ratios for cases that are difficult or impossible to form with existing forming machines and mandrels, however. In particular, the small relative of the SPW and SPH relative to the large SD makes for ratios that can near or exceed 8:1. Consequently, the cases disclosed herein utilize the two largest dimensions of SD and SPH to form the case, and, in some embodiments, load the product on its edge (as discussed in greater detail below). Thus, a full shelf depth case can be made using existing machinery in many instances, without the need for specialty equipment.

Moreover, by rotating the case 90 degrees when replenishing the retailer's shelf, a “side” of the case is reoriented to become the “top”. And, opening of the cases herein disclosed are simplified, reducing the propensity for ragged edges or tears; further, the number of perforations may be reduced when compared to known case designs. Finally, cases disclosed herein may be opened easily without the use of tools, as a lever is formed in the case, by locating the tear lines in appropriate locations, such that the user can gain a mechanical advantage when opening the case.

Finally, cases disclosed herein can offer significant cost and corrugate savings when compared to known case designs. In traditional RSC (regular slotted case) designs, the cases are pre-glued at the overlapping seams, adding a machine step, increasing material cost, and complicating storage of semi-completed blanks. Additional, known RSC designs include overlapping material that is required on the two sides with closures. In contract, the cases disclosed herein, which can be referred to as FSC (flange seal cases), reduces or eliminates waste and machine processing steps, while saving up to 20-30% in material cost.

In known case designs, elaborate tear strips, score lines, and additional features dilate the ability of the machinery to form the case. In some embodiments disclosed herein, however, scoring is limited to bottom and side portions of the case, permitting forming machines to form the case efficiently and with precision. Embodiments disclosed herein may utilize asymmetric sections that do not impede the final forming/closing operation, but can significantly impact the retail configuration of the case, yielding an aesthetically pleasing case. And, scoring on the bottom of the case, which can be hidden from the consumer in a display configuration of the case by another portion of the case, allows for aggressive cut patterns and easy tear-away. Finally, machine cut edges that the consumer may see provide for excellent shelf-appeal.

As shown in FIG. 8, a package assembly 10 comprises a case 20. The case 20 is defined by a blank 30 (FIG. 1) that has been folded from a single piece of packaging material 40 into the case 20 (FIG. 8). The case 20 is configured to contain one or more product containers 50, as shown for example in FIG. 5

In FIG. 10, it is illustrated that when the package assembly 10 is converted to the display configuration, shown, a side portion 60 (FIG. 9) of the case 20 is removed to allow the product containers 50 to be displayed on the remaining shelf-ready portion 70. The mechanism for removal of the side portion 60 from the shelf-ready portion 70 of the case 20 is discussed in greater detail below.

With regard to FIGS. 1-7, the construction of the case 20, starting with a single blank 30, is shown. Blank 30 can be constructed of any suitable or desired packaging material and can be any desirable size and shape, depending upon the shape and weight of the product containers 50 to be contained within the case 20.

For example, in at least one embodiment the blank 30 is constructed from cardboard (corrugated or otherwise). Other materials that blank 30 can be constructed from include: press-board, chipboard, SBS board, wood, one or more paper product derivatives, plastic, metal, or other materials. In some embodiments, the blank is constructed from a light weight material that may be easily and inexpensively recycled or disposed of.

As shown in FIG. 1, the blank 30 comprises several distinct sections or regions 101-115 as defined by preformed seams or fold-lines (larger sections being considered panels, smaller sections being flaps or tabs). The blank 30 has fifteen (15) sections: first section 101, second section 102, third section 103, fourth section 104, fifth section 105, sixth section 106, seventh section 107, eighth section 108, ninth section 109, tenth section 110, eleventh section 111, twelfth section 112, thirteenth section 113, fourteenth section 114, and fifteenth section 115. Second section 102 includes portions 102 a and 102 b; seventh section 107 includes portions 107 a and 107 b; and twelfth section 112 includes portions 112 a and 112 b. In at least some embodiments, the respective portions are separated by a tear line 135, and/or a second tear line 136, and/or a third tear line 137.

Turning to FIG. 2, in some embodiments, the blank 30 is assembled into case 20 by folding the first section 101 with respect to the second section 102 along the dividing line between these sections. Additionally, the blank 20 is folded along the dividing line between the second section 102 and the third section 103 to create the assembly shown in FIG. 2.

With regard to FIGS. 2 and 3, the eighth section 108 is folded inwardly along the dividing line between it and the third section 103; similarly, the sixth section 106 is folded inwardly along the dividing line between it and the first section 101. Thirteenth section 113 and eleventh section 111 are also folded inwardly along their respective dividing lines. In some embodiments, seventh and twelfth sections, 107, 112 are folded, as shown in FIG. 3, along with respective dividing lines. As will be appreciated, the order of folding can be altered, for example permitting the seventh section 107 to be folded prior to folding of the eighth section 108 and sixth section 106. The same can be said for the eleventh, twelfth, and thirteenth sections, 111, 112, and 113. The sections can be glued or otherwise held together.

In some embodiments, during the folding process the second section 102 remains horizontal. Further, all or portions of the second section 102 can be supported throughout the folding process.

Once the package assembly 10 is oriented as shown in FIG. 4, product containers 50 are loaded into the package assembly 10. As will be appreciated, in some embodiments, the product containers 50 are loaded into the package assembly 10 such that the product containers 50 are only a single container deep (in the direction in which they are being loaded) and multiple containers long. Such a configuration permits the product containers 50 to be loaded efficiently into the package assembly 10.

FIG. 5 shows the package assembly 10 having product containers 50 after they have been loaded into the package assembly 10. As shown in FIG. 5, it is evident that, in at least some embodiments, the shape of the fourth section 104 is different than that of the fifth section 105. In some embodiments, the package assembly 10 has an asymmetric top 18 (FIGS. 5 and 6).

As shown in FIGS. 5 and 6, the fifth section 105 of the top 18 is folded along the dividing line between fifth section 105 and first section 101. Additionally, the fourth section 104 of the top 18 is folded along the dividing line between the fourth section 104 and the third section 103. Once these steps are completed, the package assembly 10 takes on the configuration shown in FIG. 6.

As illustrated in FIGS. 6 and 7, the package assembly 10 is completed by folding the ninth and tenth sections 109, 110 along the respective dividing lines between these sections and the fourth and fifth sections 104, 105, respectively. Additionally, the fourteenth and fifteenth sections 114, 115 are folded along the respective dividing lines between these sections and the fourth and fifth sections 104, 105, as illustrated.

As further shown in FIG. 7, the package assembly 10 is ready to be placed on a pallet and/or stacked for shipping. In particular, due to the construction of the package assembly 10, it can support additional package assemblies 10 stacked on top of it. The corners 28 of the package assembly 10 provide structural integrity to the package assembly 10 as these portions of the package assembly 10 include overlapping sections (e.g., 107 b, 108, 109). Thus, the package assembly can be readily stacked and shipped in the orientation shown in FIG. 7.

In some embodiments, the package assembly 10 comprises a corrugated cardboard material. In some embodiments, the package assembly (e.gi., corrugated cardboard) has flutes 46 (represented by lines in FIGS. 1 and 7). At least some of the flutes 46 can extend vertically when the package assembly is in the shipping configuration (e.g., flutes 46 of the first section 101). Such a configuration can provide structural integrity (e.g., columnar strength) for stacking of the package assembly. In some embodiments, because the package assembly 10 is formed from a single piece of material, the flutes 46 extend in the same direction throughout the blank 30 (FIG. 1). In some embodiments, one or more of the tear lines (e.g., 135, 136, 137) extends perpendicularly relative to the flutes 46, as illustrated via the flutes 46 in the fourth section 104 in FIG. 1. In some embodiments, as least a portion of the one or more of the tear lines (e.g., 135, 136, 137) extends perpendicularly relative to the flutes 46. Further, in some embodiments, at least a portion of one or more of the tear lines (e.g., 135, 136, 137) is +/−15° from perpendicular relative to the flutes 46 (e.g., in some embodiments, a portion of the tear line 135 is within 15° from perpendicular relative to the flutes 46). In some embodiments, at least a portion of one or more of the tear lines (e.g., 135, 136, 137) is +/−10° from perpendicular relative to the flutes 46 (e.g., in some embodiments, a portion of the tear line 135 is within 10° from perpendicular relative to the flutes 46). In some embodiments, the flutes 46 are parallel to the long dimension of the blank 30.

In some embodiments, the flutes 46 are arranged so that they are parallel to one or more of the tear lines (e.g., 135, 136, 137) or portions of the tear lines. In some embodiments, the flutes 46 are perpendicular to the long dimension of the blank 30. At least some of the flutes 46 can extend horizontally when the package assembly is in the shipping configuration.

It will be appreciated that there is a gap 44 between the fourth section 104 and the fifth section 105. In some embodiments, the package assembly 10 has one or more hand holes or enlarged openings for opening the package assembly 10 along the tear lines (e.g. 135, 136, 137). In some embodiments, a hand hole is situated along the division between the fourth section 104 and the fifth section 105.

As shown in FIG. 8, the package assembly 10 is reoriented so that it can be prepared for placement on a store shelf. Prior to placement on the store shelf, however, the package assembly 10 needs to be deconstructed, as shown for example in FIG. 9. In particular, the side portion 60 is removed from the shelf-ready portion 70. In order to remove the side portion 60 from the shelf-ready portion 70, the user can simply pull upwardly, in the direction of arrow 48. As the user pulls on the side portion 60, the tear line 135 will begin to tear, separating portion 102 a from portion 102 b. In some embodiments, the orientation shown in FIG. 8 is the shipping orientation. In this orientation, however, in some embodiments, the tear line 135 acts as part of the support when stacking the package assembly 10.

In some embodiments, the tear line 135 extends only a portion of the length between portions 102 a and 102 b. In some embodiments, however, it extends the entire shared length (e.g., from the seventh section 107 to the twelfth section 112). In some embodiments, the tear line 135 includes one or more sections that are “clear cut”—cut entirely through the blank 30. In some embodiments, the tear line 135 includes one or more sections that are “skip cut”—cut portions alternating with uncut portions, each portion being ¼″ in length, for example. In some embodiments, 30-60% of the length of the tear line 135 between seventh section 107 and twelfth section 112 is clear cut and 40-70% of it is skip cut.

In some embodiments, the second tear line 136 includes one or more sections that are clear cut and one or more sections that are skip cut. In some embodiments, 30-60% of the length of the second tear line 136 is clear cut and 40-70% of it is skip cut.

Similarly, in some embodiments, the third tear line 137 includes one or more sections that are clear cut and one or more sections that are skip cut. In some embodiments, 30-60% of the length of the third tear line 137 is clear cut and 40-70% of it is skip cut. In some embodiments, the entirely of the third tear line 137 is cut through and none of it is skip cut.

In some embodiments, all or portions of the dividing line between 112 a and 112 b of the twelfth section 112 include a second tear line 136 (FIG. 1). Additionally, in some embodiments, all or portions of the dividing line between 107 a and 107 b of the seventh section 107 include a third tear line 137. Consequently, when the user separates the side portion 60 from the shelf-ready portion 70, a minimal amount of force is required and the result is a clean-looking separation between the side portion 60 from the shelf-ready portion 70, without delamination of the material or rough or jagged edges. In some embodiments, a tear line 135 extends along the entire length between the seventh section 107 and the twelfth section 112. Further, in some embodiments, a third tear line 137 extends the entire length of the seventh section 107. In embodiments, the tear line 135 and the third tear line 137 are the only tear lines that tear when separating the shelf-ready portion 70 from the side portion 60. In some embodiments, the tear lines (e.g., 135, 136, 137) comprise tear lines or tear strips.

FIG. 10 shows the remaining shelf-ready portion 70 after the side portion 60 has been complete removed therefrom. The shelf-ready portion 70 can be placed on a shelf.

FIG. 11 further illustrates the second tear (or perforation) line 136 after separation of the shelf-ready portion 70 from the side portion 60. Any of the tear lines 135, 136, 137 can be formed by scoring. Further, aggressive scoring and/or perforation of the package assembly 10 along the second perforation line 136 permits easy separation of the shelf-ready portion 70 from the side portion 60 without unduly impacting the strength of the case 20 when in the shipping orientation. Moreover, and with regard to FIGS. 1, 3, and 11, it will be appreciated that the third tear line 137 is covered by the ninth section 109, while the second perforation line 136 is covered by the fourteenth section 114 even after the shelf-ready portion 70 has been separated from the side portion 60. In some embodiments, ninth section 109 is larger than section 107 b and fourteenth section 114 is larger than section 112 b such that relevant tear line (136, 137) is masked by the ninth section 109 and/or fourteenth section 114.

In some embodiments, the dividing lines between adjacent sections server as fold lines and, in some embodiments, comprise perforations in order to facilitate easier folding.

The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims. 

What is claimed is:
 1. A package assembly comprising: a case formed from a single piece of packaging material, the case having a filling configuration and a display configuration; the case having a first side and a second side opposite the first side, wherein a first tear line extends along a first side of the case and the second side of the case defines a gap opposite the tear line; the case further having a front when the case is in the display configuration, the front defining a second tear line, the second tear line being at least partially masked in the display configuration by a flap that extends over the second tear line.
 2. The package assembly of claim 1 further comprising a third tear line.
 3. The package assembly of claim 1, wherein the packaging material is corrugated cardboard defining flutes.
 4. The package assembly of claim 3, wherein the case further has a shipping configuration, wherein, when the case is in the shipping configuration, the flutes extend vertically.
 5. The package assembly of claim 1, wherein the case has a front in the display configuration, the front of the case having three overlapping sections.
 6. The package assembly of claim 5, wherein the case has a back in the display configuration, the back of the case having three overlapping sections.
 7. The package assembly of claim 6, wherein, in the display configuration, the surface area of the back is greater than the surface area of the front.
 8. The package assembly of claim 1 having exactly fifteen sections.
 9. The package of claim 8, wherein exactly two of the sections have tear lines.
 10. The package assembly of claim 8, wherein exactly three of the sections have tear lines.
 11. The package assembly of claim 1, wherein the second tear line includes a portion that is skip cut and a portion that is clear cut.
 12. The package assembly of claim 1, wherein 30-60% of the length of the second tear line 136 is clear cut and 40-70% of it is skip cut.
 13. The package assembly of claim 2, wherein the third tear line includes a portion that is skip cut and a portion that is clear cut.
 14. The package assembly of claim 13, wherein 30-60% of the length of the third tear line 136 is clear cut and 40-70% of it is skip cut. 